Battery Tray Protection Structure for EV Impact Energy Dissipation
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Solution Overview
Problem
Existing battery trays for electric vehicles lack effective protection against impacts, which can damage the battery core, leading to safety concerns due to their weak protection capabilities.
Innovation Solution
A battery tray design featuring a first protection plate with a sandwich structure of high-strength plates and an energy-absorbing cellular plate, combined with a second protection plate of lower wave impedance, strategically positioned to absorb and dissipate impact energy, reducing stress wave propagation and enhancing anti-impact capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a simple tray structure is used, then manufacturing cost and complexity are reduced, but protection capability against impact is insufficient
Solution Approach 1:
The protection plate is divided into multiple functional layers: a first protection plate with energy-absorbing cellular structure and high-strength plates, and a second protection plate with lower wave impedance. This segmentation allows each layer to perform specific functions (energy absorption, stress wave reflection, and dissipation) that collectively enhance protection capability while managing structural complexity.
Solution Approach 2:
The first protection plate combines different materials with distinct properties: energy-absorbing materials (foam, rubber, plastic) in the cellular structure, and high-strength materials (metal, glass fiber reinforced plastic) in the plates. This composite structure achieves both energy absorption and structural strength, resolving the contradiction between protection capability and structural simplicity.
2Strength
If high-strength materials are used throughout the tray, then protection capability is improved, but weight and manufacturing cost increase
Solution Approach 1:
Different regions of the protection plate are assigned different material properties and functions. The cellular structure uses energy-absorbing materials at strategic locations, while high-strength plates are positioned where structural support is needed. The second protection plate uses lower wave impedance materials where stress wave dissipation is the primary function. This localized material assignment achieves impact resistance without uniformly increasing weight.
3Loss of energy
If a single-layer protection plate is used, then device complexity is reduced, but energy absorption and stress wave dissipation capabilities are insufficient
Solution Approach 1:
The protection system is segmented into two distinct protection plates with different wave impedance characteristics. The first protection plate (higher wave impedance) reflects incoming stress waves, while the second protection plate (lower wave impedance) dissipates the reflected waves. This segmentation creates a multi-stage energy management system that enhances overall energy dissipation capability.
Solution Approach 2:
The first protection plate acts as an intermediary between the impact source and the second protection plate. It absorbs initial impact energy through its cellular structure and reflects stress waves toward the second plate, which then dissipates the energy. This intermediary arrangement creates a progressive energy management system that improves total energy dissipation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design significantly improves the battery tray's ability to absorb and dissipate impact energy, reducing the influence on the battery module and enhancing the overall safety and protection of the battery pack.
Implementation Method 1
the first protection plate includes an energy-absorbing plate and high-strength plates located on two sides of the energy-absorbing plate, the energy-absorbing plate includes a cellular structure
Implementation Method 2
a wave impedance value of the second protection plate is less than a wave impedance value of the high-strength plates
Data Source
AI summary
A battery tray includes: a tray body includes a tray bottom plate and a tray side beam located on a first side of the tray bottom plate, and the tray side beam and the tray bottom plate defines a battery accommodating cavity accommodating for accommodating a battery module or a cell; a first protection plate includes an energy-absorbing plate and high-strength plates located on two sides of the energy-absorbing plate, the energy-absorbing plate includes a cellular structure, and the first protection plate is fixed on the tray bottom plate; and a second protection plate, where a first surface of the second protection plate is coupled to the first protection plate, a second surface of the second protection plate is coupled to the tray body, and a wave impedance value of the second protection plate is less than a wave impedance value of the high-strength plates.